Rooftile support for photocell panel

ABSTRACT

The invention relates to a roof tile/roof slate/wall plate 1 made of a plate of clay, ceramic, concrete, fiber cement or synthetic, serving as a carrier for a solar panel 6 with photovoltaic solar cells 7 to be attached to its upper side where said solar panel 6 is attached form-fittingly to the upper side of the roof tile/roof slate/wall plate with at least two sides opposite to one another at the inner edges of a recess of a roof tile/roof slate/wall plate indent, and where the extensions 5, due to their own flexibility, are engaged in a snap-in manner particularly form-fittingly in recesses 4 of the roof tile/roof slate/wall plate indentation 2.

The invention relates to roof tile/roof slate/wall plate made of a plateof clay, ceramic, concrete, fiber cement or synthetic, serving as acarrier for a solar panel with photovoltaic solar cells attached on theupper side. The solar panel is form-fittingly attached to the upper sideof the roof tile/roof slate/wall plate with at least two sides oppositeto one another at the inner edges of an indent of a roof tile/roofslate/wall plate.

European patent application EP 0 440 103 A2 discloses a solar panelattached to the upper side of a roof tile. The solar panel is attachedform-fittingly such that the material of the roof tile/roof slateprotrudes at least on two opposite sides such that it reaches over onearea, particularly the edge of the solar panel which secures the solarpanel from being lifted off. The solar panel is, particularly fromabove, pressed onto the roof tile and, due to its own flexibility, hooksinto a recess of the roof tile.

It became apparent that roof tiles have liberal production tolerancesmaking the fit of the solar panels insufficient; they are either seatedtoo loosely on the roof tile or are too large to fit.

JP-A-31 24 070 discloses solar cells that are mounted in a common framewith metal hooks attached to the bottom of the solar cells such that thehooks engage in the frame. Due to this particular mounting method, thesolar cells are protected from mechanical damage due to thermalexpansion.

It is the object of the invention to improve a roof tile/roof slate/wallplate with solar panel such that the solar panel will always have asecure and precise hold without damaging the solar cells duringinstallation, even with the liberal production tolerances.

This object is attained by the embodiment according to the invention.

The flexible extensions of the solar panel, protruding on the sides, canbe fitted to the diverse deviations in dimensions providing always asecure and strong hold. In this manner, the solar panels will fit intothe roof tile/roof slate/wall plate, even when the inside dimensions ofthe roof tile/roof slate/wall plate are significantly smaller thanintended.

It is particularly advantageous if the recesses cover a length that is afraction of the entire length of the inner edge. These recesses may begroove sections, longitudinal holes, pockets, and/or bore holes. Theextensions should also be carried by a frame or built into, particularlyjoined to, a frame surrounding the solar cell(s).

It is most advantageous if the extensions protrude at the bottom side ofthe solar panel in a beveled downwards fashion.

In this manner, the extensions are located very low at the solar panel,finding support relatively low at the roof tile, thereby having themodule itself seated high on the roof truss, allowing the upper surfaceof the solar panel to be in line with the upper surface of the rooftile, and thus avoiding dirt from depositing on the rims and extensions.

Secure sealing is achieved when a longitudinal rabbet profile protrudesto the side at the upper edge of the frame and butts tightly with theroof tile/roof slate/wall plate.

A particularly tight hold of the solar panel on the roof tile/roofslate/wall plate is achieved if numerous micro containers (micropheres),containing glue, are attached to the surface of the extensions. Thesemicro containers may contain as one part a first component and as secondpart a second component of a two component adhesive.

A particularly good bond and optimal hold of the photovoltaic elementsin the frame of the solar panel is achieved if a non-metallic, elasticmaterial, particularly silicone, is applied between the photovoltaicelement and the frame. The silicone will build a watertight seal aftercuring. The silicone will form a chemical compound with the glass of thephotovoltaic element and with the synthetic material, particularlysilicone, of the frame. This results in an unbreakable bond whichprotects the solar cells from the infiltration of corrosive atmospheres.

Chamfering of the solar panel's glass pane and an overlapping of thecurable synthetic material, particularly silicone, provides a specialprotection of the edges of the hardened glass panes, which areparticularly sensitive to breakage.

The frame forms a level plane with the glass pane. With this design,rain water can run off smoothly without obstruction and without dirtparticles being able to collect on the edges of the solar panel. Thetransparency of the solar panel's glass pane remains intact andlong-term cleanliness is maintained. Cleaning of the solar panel is notnecessary.

Simple and secure wiring is achieved if a cable support, fastened,particularly joined, to the solar panel, protrudes downwards on thebottom side of the solar panel.

The roofing element photovoltaic system according to the inventionfeatures a number of significant advantages. The roofs can initially becovered in a conventional manner. The solar panels can be pressed intothe roof tiles at a later date and anchored in a non-slipping manner;the energy supply can be constructed successively, all without the needto uncover or change the roof.

It is particularly advantageous if a profile is fastened to at least onebut preferably two opposite sides of the solar panel, with said profilefeaturing at least one flexible blade pointing downwards, and with theend of the blades forming the extensions that snap into at least onerecess of the indent of the roof tile/roof slate/wall plate. Thisensures a secure hold of the solar panel even over long periods,especially if the profile is made of stainless steel or aluminum.

Destructive warping of the solar cells is absolutely prevented if one ofthe measures according to claims 25 to 28 is provided.

Further details and advantageous refinements of the invention are setforth in the following description and associated drawings of thepreferred embodiment, of which

FIG. 1 is a section through a roof tile/roof slate;

FIG. 2 is a top view and a side view of the roof tile/roof slate/wallplate;

FIG. 3 is a section through the side edge of the solar panel in theregion of an longitudinal side;

FIG. 4 is a section through the side edge of the solar panel in theregion of the narrow side with the joined cable support;

FIG. 5 is a section through the side edge of the solar panel in theregion of the narrow side with the joined cable support;

FIG. 6 is a section through the solar panel according to FIG. 5;

FIG. 7 is a section through an embodiment where the carrier plate of thesolar panel forms the flexible extensions on the side of the solarpanel;

FIG. 8 is a section through the roof tile/roof slate/wall plate in athird embodiment with holding profiles made of metal;

FIG. 9 is a section through the roof tile/roof slate/wall plate in afourth embodiment with holding profiles made of metal;

FIG. 10 is the bottom side of the third or fourth embodiment withbracing ribs;

FIG. 11 is the upper side of the third or fourth embodiment withweakening recesses;

FIG. 12 is a section through a roof tile/roof slate/wall plate withdeflecting holding profiles or brackets;

FIG. 13 is a section through the fastening region with spring pinelements; and

FIG. 14 is a section through the fastening section with inserted adapterbushings.

A roof tile/roof slate/wall plate, in the following called roof tile 1,is made of clay, ceramic, concrete or synthetic and features, asillustrated in FIG. 1, an indent 2 that is open on the top, giving theroof plate a wide U-shaped cross section with its free ends being benttowards the outside to create the traditional interlocking rabbetoverlaps.

Individual recesses 4 are placed on the sides, in the inner edges 3 ofthe indent 2, with extensions 5 of the solar panel 6 engaging in theserecesses. Thus, the solar panel 6 covers the top side of the indent 2 inits entirety. The solar panel 6 is made with solar cells (photovoltaicelements) 7 surrounded by a frame 8.

The extensions 5, made of a soft material, particularly of a softsynthetic (silicone), are joined to the two longitudinal sides on theoutside of the rectangular frame 8, as illustrated in FIGS. 1 and 2. Theframe 8 can be made of the same material. The extensions 5 do not coverthe entire length of the side edge of frame 8, rather each side of theframe features two or more individual extensions 5 that engageform-fittingly in correspondingly shaped individual recesses of theinner edges or inner side walls.

In this manner, the recesses 4 have a length that is only a fraction ofthe entire length of the inner edge 3. These recesses 4 may be groovesections, longitudinal holes, pockets, and/or bore holes.

The extensions 5, protrude, as illustrated in FIG. 3, at the bottom edgein a downwards bevelled fashion with an angle of approx. 45 degrees suchthat the frame 8 is on the roof tile 1 at such a height, that there isno indent above the solar panel, or only a slight indent. With such adesign, shading of the solar panel by the edge of the roof tile isnegligible ensuring light incidence even when the sun is at a low angle.

The special design of extensions 5 underneath the solar panel 6 createsa spring/clamp effect to secure the solar panel 6 to the roof tile.

A longitudinal rabbet profile 9 protrudes to the side in an approximatehorizontal manner at the upper edge of the frame 8 and butts tightlywith the inner edge 3. Numerous micro containers 12, containing glue,may be attached to the surface of the extensions 5. These microcontainers may contain as one part a first component and as second parta second component of a two component adhesive such that when pressingthe extension 5 into the recess 4, the micro containers burst, theircontents mix and form a fast hardening adhesive.

Located between the photovoltaic elements or solar cells 7 and the frame8 is a non-metallic, elastic material, particularly a synthetic(silicone) 10 that will, after curing, form a watertight connectionbetween these parts at their edges and form a chemical compound withthese edges.

A particularly good bond between the frame 8 and the solar panel 6 isachieved when the upper edge 14 of the solar panel's 6 glass pane 13,the one pointing to the light, is chamfered such that the chemicallyreacting synthetic (silicone) 10 reaches over the glass pane resultingin a stronger bond between the frame 8 with the solar panel 6.

An additional advantage of this arrangement with the synthetic 10reaching over the edge of the glass pane 13 is the protection of theseedges from mechanical and chemical attack. This is especially important,because the glass pane is hardened and particularly sensitive to shock.

This frame structure 8-10 allows for rain water to run off withoutobstruction, preventing dirt-forming particles from being deposited onthe edges. This is a significant advantage over all known solar-panelframes.

Protruding downwards, a cable support 11 is joined to the frame 8 at thebottom side of the solar panel 6, as illustrated in FIGS. 2 and 4. Onecable support each is located on the bottom narrow side and on the topnarrow side of the solar panel 6.

The embodiment illustrated in FIGS. 5 and 6 deviates from the embodimentshown in FIGS. 1 through 4 such that the extensions 5 have a camberedexterior shape with a horizontal main axis (longitudinal axis). Theseextensions are particularly flexible if they are made of a very softmaterial such as moss rubber, and/or if they are hollow on the inside(hollow body, hollow profile), as shown on the left side of FIGS. 5 and6. In one special embodiment, the extensions have an oval sectionalshape.

As illustrated in FIG. 11, the carrier plate 6a of the solar panel maybe made of a flexible material from which hook-shaped parts 5 orextensions or tongues protrude on each side that snap into the recesses4 of the roof tile/roof slate or the wall plate.

By pressing in the polymer pv. module, the flexible hooks are benttowards the inside over the adaption geometry and then engage in thecorresponding indents in the roofing elements.

Over the length of the appendage, particularly through a bent elasticarea (18a) (FIG. 12), the spring distance of the snap-in connection isdetermined; over the bending points, the curvature of the polymer pv.module is created.

The ribbing keeps the bending forces away from the solar cells. Initialtension in the roofing element is created by a slightly larger size ofthe carrier plate in the roofing element.

Through the geometry of the snap-in connection in combination with theweak bending points, the pv. module's curvature will always pointupwards because of this slightly larger size.

The solar cells are mounted on a carrier plate (6a) made of ceramic,concrete or glass reinforced with glass fiber or glass spheres, asillustrated in FIGS. 7, 8, 9, 10. As illustrated in FIG. 11, notches 20are worked into the carrier plate 6a between the solar cells such thatthe carrier plate can be bent at these weaker points 20 without thebending forces bending the solar cells in a damaging manner. Bending ofthe solar cells is also prevented by the torsion-proof ribbing 21located underneath the solar cells. The thickness of the carrier platebetween the solar cells is small enough that the carrier plate can bebent (curvature towards the inside).

Profiles 17 are, according to FIGS. 8 and 9, fastened to at least onebut preferably two opposite sides of the solar panel, with said profilesfeaturing at least one flexible blade 18 pointing downwards with the endof the blades forming the extensions 19 that snap into at least onerecess of the indent of the roof tile/roof slate/wall plate. Thus,adaptation tongues are or flexible hooks, particularly profiles areattached as snap-in fasteners that engage in the recesses of the rooftile upon bending. When the bending relaxes, the polymer module remainsattached to the roof tile under a small tension. The profile 17 featuresin its upper region a recess, particularly a longitudinal groove(longitudinal channel) 16 where the side edge of the solar panel isform-fittingly inserted. The profile 17 is made of metal having a highstrength-to-weight ratio, particularly of stainless steel or aluminum.In one special embodiment, the flexible blade 18 covers either theentire length or only a short distance of the entire length of the solarpanel.

The tongues 5 are designed such that they can deflect as the module ispressed in. The slight tension of the carrier plate, combined with aslight curvature adjusts for tolerances in the roof tile. Torsiontolerances among the adaptation grooves can be corrected through slighttwisting of the carrier plate. The blue annealed V4A spring element 17,18, 19 engages in the adaptation geometry of the roof tile/roof slate.The spring element is pushed into indentations of the carrier plate andlocked in position by the subsequent laminating process.

Instead of or in addition to the spring elements 17, 18, 19, spring pinelements 22 may be attached to the solar panel, as illustrated in FIGS.13 and 14, where said spring pin elements are loaded by a compressionspring 23 and their front pointed tip 24 engages in the correspondinglyshaped recess 25 of the roof tile/roof slate/wall plate. The recess 25may be made from a bearing part 26, particularly in shape of a bushingmade of metal or synthetic and be cast, pressed or glued into thematerial of the roof tile/roof slate/wall plate. This presents anespecially secure hold regardless of the material of the roof tile/roofslate/wall plate.

Roof tiles made of clay are burnt and have tolerances in all directionsdue to the production process. These tolerances are adjusted for throughthe design of the carrier plate. The carrier plate with the solar cellsis hermetically sealed in fluoro-polymer resin. An unbreakable chemicaland mechanical bond between the carrier material and the solar cells isachieved through adhesive agents and holes in the carrier plate.

In its outer region, the sheeting of the cable is made of the samepolymer as the one enclosing the module. This ensures a mechanicallytear-proof and weather-resistant, corrosion-proof electrical connection.

The following features are particularly advantageous at this rooftile/roof slate/wall plate:

The synthetic enclosing the solar panel 6 is a fluoro-polymer. Using anadhesive agent, the polymer synthetic is chemically joined with thecarrier material. The polymer synthetic may be joined mechanically withthe carrier material by through-holes, indentations, or bore holes.

The tongues of the carrier plate engage in the adaptation geometry ofthe roof element such that a slight tension curvature adapts the pv.module to the roof tile such that production tolerances of the roofingelement in the longitudinal, horizontal and torsion planes are adjustedfor. The adaptation geometry of the carrier plate is thus a flexibleconstruction (snap-in connection).

The electrical wiring consists of three components: a cable, a firstsheeting made of a high-temperature resistant polymer, and a secondsheeting made of the same polymer as the one enclosing the module. Inthis manner, the cable is hermetically sealed into the pv. module andmechanically stable. The electrical cable can be attached to a U-shapedguide channel. Wiring of the solar panel is carried out on the back sideof the carrier plate, particularly in printed circuit technology.

I claim:
 1. Roof tile/roof slate/wall plate made of a plate of clay,ceramic, concrete, fiber cement or synthetic, formed with a plurality ofrecesses, in combination with a solar panel (6) with photovoltaic solarcells to be attached to its upper side, whereinsaid solar panel (6) isattached form-fittingly to the upper side of the roof tile/roofslate/wall plate with at least two sides opposite to one another at theinner edges of a recess of an indent of a roof tile/roof slate/wallplate, flexible extensions (5, 19) are positioned on the side of thesolar panel, and the extensions (5, 19), due to their own flexibility,engage in a snap-in manner, in recesses (4) of the roof tile/roofslate/wall plate indentation (2).
 2. Roof tile/roof slate/wall plateaccording to claim 1, whereinthe solar panel (6) features on each of twosides opposite to one another two or more individual extensions (5) thatrest form-fittingly in correspondingly shaped individual recesses (4) ofthe inner edges (3).
 3. Roof tile/roof slate/wall plate according toclaim 1, wherein the recesses (4) engage at a bottom side edge of theroof tile/roof slate/wall plate.
 4. Roof tile/roof slate/wall plateaccording to claim 1, wherein the extensions (5) are made of an elasticmaterial.
 5. Roof tile/roof slate/wall plate according to claim 1,wherein the recesses (4) have a length that is a fraction of the entirelength of the inner edge (3).
 6. Roof tile/roof slate/wall plateaccording to claim 1, wherein the recesses (4) have a shape selectedfrom the group consisting of groove sections, longitudinal holes,pockets, and bore holes.
 7. Roof tile/roof slate/wall plate according toclaim 1, wherein the extensions (5) are carried by a frame surroundingthe solar panel (6).
 8. Roof tile/roof slate/wall plate according toclaims 1, wherein the extensions (5) protrude at the bottom side of thesolar panel in a downwardly bevelled fashion.
 9. Roof tile/roofslate/wall plate according to claim 1, wherein a longitudinal rabbetprofile (9) protrudes to a side at an upper edge of the frame (8) andbutts tightly with the roof tile/roof slate/wall plate (1).
 10. Rooftile/roof slate/wall plate according to claim 1, wherein a plurality ofmicrocontainers (12) containing glue are attached to a surface of theextensions (5).
 11. Roof tile/roof slate/wall plate according to claim10, wherein the micro containers (12) contain as one part a firstcomponent, and as second part, a second component of a two componentadhesive.
 12. Roof tile/roof slate/wall plate according to claim 1,wherein a non-metallic, elastic material (10), is applied between thephotovoltaic element (7) and the frame (8) and this material builds awatertight seal after curing.
 13. Roof tile/roof slate/wall plateaccording to claim 1, wherein a cable support (11) is fastened, to thesolar panel and protrudes downwards on the underside of the solar panel(6).
 14. Roof tile/roof slate/wall plate according to claim 1, whereinthe frame (8) is in line with a glass pane (13) of the solar panel (6),and where edges of the glass pane (13) pointing to the sun are chamferedall around.
 15. Roof tile/roof slate/wall plate according to claim 1,wherein the extensions (5) form part of a hollow body, made of anelastic material.
 16. Roof tile/roof slate/wall plate according to claim1, wherein the extension has an oval cross section.
 17. Roof tile/roofslate/wall plate according to claim 1, wherein a section of a profile(17) is fastened to two opposite sides of the solar panel, with saidprofile featuring at least one flexible blade (18) pointing downwardswith the end of the blades forming the extension(s) (19) that snap intoat least one recess of the roof tile/roof slate/wall plate indent. 18.Roof tile/roof slate/wall plate according to claim 1, wherein theflexible blade (18) features a bent spring region (18a) to adjust fortolerances.
 19. Roof tile/roof slate/wall plate according to claim 1,wherein the profile (17) features in its upper region a recess, (16)into which the side edge of the solar panel engages.
 20. Roof tile/roofslate/wall plate according to claim 1, wherein the elastic blade (18)covers at least a short portion of the length of the solar panel. 21.Roof tile/roof slate/wall plate according to claim 1, wherein theprofile (17) is made of a metal having a high strength-to-weight ratio.22. Roof tile/roof slate/wall plate according to claim 1, wherein theextensions attached to the solar panels comprise spring-loaded pins(22).
 23. Roof tile/roof slate/wall plate according to claim 1, whereinouter edges (24) of pins (22) are shaped in a way which matches theinner shape of recess (4) of the roof tile/roof slate/wall plate. 24.Roof tile/roof slate/wall plate according to claim 1, wherein therecesses (4) of the roof tile/roof slate/wall plate are made from abearing part, and are cast, pressed or glued into the material of theroof tile/roof slate/wall plate.
 25. Roof tile/roof slate/wall plateaccording to claim 1, wherein a carrier plate portion (6a) of the solarpanel (6) is made of glass.
 26. Roof tile/roof slate/wall plateaccording to claim 1, wherein the carrier plate of the solar platefeatures protruding ribs (21) on a bottom side thereof to make theregion of the solar cells (7) more rigid.
 27. Roof tile/roof slate/wallplate according to claim 1, wherein the bottom side is free of ribs in aregion of spaces between the solar cells (7).
 28. Roof tile/roofslate/wall plate according to claim 1, wherein weakening notches (20),are formed in the carrier plate (6a) in the region of the spaces betweenthe solar cells (7).
 29. A solar panel (6), comprising a generallyrectangular base plate (6a), a plurality of photovoltaic cells (7)secured to an upper surface of said base plate, a frame (8) surroundingsaid plurality of photovoltaic cells (7), and at least two extensions(5) of a resilient material protruding from each of at least twoopposing sides of said solar panel, out of a plane defined by saidrectangular base plate, in a direction away from said upper surfacebearing said photovoltaic cells (7).